Additive Manufacturing Opportunities within DoD …sae.org/events/dod/presentations/2014/11-19/additive_manufacturing...Additive Manufacturing Opportunities within DoD Maintenance

Additive Manufacturing Opportunities within DoD

Maintenance

ModeratorCAPT Frank Futcher

Director, Navy Business Operations Office, Navy Staff, OPNAV N415

Mr. Chris Root

Lead for Advanced Aircraft Technologies and Office of Research and

Technology Applications (ORTA), NAVAIR In Service Support Center,

Fleet Readiness Center Southwest

Mr. Tom Naguy

Division Chief, Life Cycle Management Division, Directorate of

Logistics, Headquarters Air Force Material Command,

Wright Patterson AFB

Ms. Stacey Clark Kerwien

Deputy Division Chief, Materials, Manufacturing and Prototype

Technology, US Army Armament Research, Development and

Engineering Center (ARDEC)

Presented to:

Presented by:

NAVY Additive Manufacturing

3

DoD Maintenance Symposium 2014

Chris RootNAVAIR Fleet Readiness Center Southwest

Office of Research & Technology Applications

18 November 2014

Examples of Navy Involvement in AM

Rapid Manufacturing & RepairCase Study: Casting Cores

Cost & Time Savings: $4k & 4 weeks

Problem/Challenge:

– Providing low quantity castings for

fleet needs

Solutions/Results:

–System for printing sand casting

molds and cores – skips cost and lead

time associated with making a pattern

to pack sand around

Benefit/Impact:Costs – Slight cost decrease

Time – Substantially reduces lead time

Weapon System – Any system that uses

castings

Contacts/Learn More About It:

Kyle Morris NUWC-Keyport 360-396-1939

General PatternGeneral Pattern

Distribution Statement A: Approved for public release; distribution is unlimited. NUWC-Keyport release #12-003

RARE Parts ProgramCase Study Part ___Vacuum Rotor_______

Weapon System___Submarines__________

Cost & Time Savings _$20k & 30 weeks____

Problem/Challenge:• Vacuum Rotor – Part can be hard to get. Cost is

$19K, lead time 48 weeks.

Solutions/Results:• Part reverse engineered and CAD model created

by TRF-King’s Bay. Mold modeled at NUWC-

Keyport, and mold will be poured by Naval Foundry

& Propeller Center (NFPC) Printed mold using Ex

One S15 system, cast parts at local foundry Cost

$14K, lead time 8 weeks.

Benefit/Impact:• Costs – $20k savings per year based on 4 units

annually

• Time – 30 week lead time reduction – better suits

emergent needs

• Weapon System – Vacuum / priming pump used

on subs

Contacts/Learn More About It:

___________________________________________Kyle Morris, 360-396-1939

Distribution Statement A: Approved for public release; distribution is unlimited. NUWC-Keyport release #13-016

Distribution Statement A – Approved for public release; distribution is unlimited

Fleet Readiness Center AM Capabilities

Selective Laser Sintering (SLS)

Fused Deposition Modeling (FDM)

Stereo Lithography Apparatus (SLA)


Rapid Prototyping and Testing

• Form and fit check

• High impact to mission readiness – quick response

• Machining / manufacturing guide

• Turn-around time after CAD modeling: 1-2 days

Custom Engineering Investigation Test

Apparatus Parts.

8


Trim Tools and Drill Templates

• Types

– Scribe Tool• Edge of tool is net

• Scribe is used to transfer EOP

– Off Set Tool• Tool edge is inset

• Provides guide surface for cutting tool

• Prevents inadvertent removal

– Drill templates• Precision location

• When to use FDM

– Complex shapes

– Ergonomic light weight

– More stable than fiberglass in high humidity environments

~18”R


Sheet Metal Press Form Tooling

• Demonstrated Applications

– Hydro forming

– Rubber pad forming

• Demonstrated Tooling

– Male & female, blow down tools

– Pressure Intensifiers

– Matched male & female tools

– Backfilled tools

• Demonstrated Conditions

– Range of alloys and thickness tested

– Demonstrated forming pressures up to

10KSI

– Variety of tools >100 cycles, some >500

cycles

– Large jointed tools have been tested

• Tooling Example

– $200 material, 8-hour build

10


Rapid Composite Tooling

• 3D model generated from laser scan of actual component.

• Tool printed with polyphenylsulfone (PPSF), covered with a layer of paste adhesive to fill in inconsistencies and wrapped with Teflon tape (for a sealed releasable surface).

• Part removal from tool was relatively easy.

– Tool was intact, not damaged, and could be re-used.

• Hat inner surface was smooth from Teflon tape and part surface.

11


AV-8B Hard Landing and Repair

LANDING APPROACH

12

3D SOLID CAD MODELING AND

AM MADE THE ONE WEEK TURN

AROUND POSSIBLE.

Naval Additive Manufacturing Technology Interchange Group

ONR, NAVAIR, NAVSEA, NRL, NUWC

The Navy sponsored technical group promotes the accelerated

introduction of additive manufacturing into Navy weapon systems

in order to reduce total ownership cost, enhance operational

availability, and promote rapid response to the warfighter.

AM Technical Objective: • Identify opportunities for AM that will enhance operational fleet

readiness, reduce energy consumption, and enable parts on

demand manufacturing by defining the Warfighter Payoff and

enhanced naval capabilities.

• Facilitate the exchange of expertise in additive manufacturing

to promote collaboration and leveraging of Navy resources by

identifying existing AM Naval applications and organizational

capabilities. The current state of the technology will be

assessed through technology cost-benefit analysis and case

studies.

• Identify AM science and technology challenges, and define the

approaches needed to address these challenges. Results will

be used to develop a Navy roadmap and S&T investment

strategy designed to accelerate the introduction of innovative,

high impact AM technology into Navy weapon systems.

Applications

Current Focus AreasDelivering a Naval AM Roadmap that

• Design Innovations

• Rapid Response and Fielding to Warfighter through AM

• Advanced Materials

• Qualification and Certification of Technology and Materials

• Life Cycle Sustainment

Future Focus• Navy foundation will build a collaborative program to advance

the science and use of additive manufacturing for Navy

applications

• Generate an official COI Charter

Benefit to the Warfighter• Reduced Total Ownership Costs

• Reduced parts cost (approx 45-55%)

• Infrastructure, time, labor savings (89% time)

• Conservation of strategic material (>86% savings)

NAVAIR AM ROADMAP Overview

14

NAVAIR Transformative Goals#1 - Field AM Parts

#2 – Demonstrate Rapid

Qualification/Certification

# 3 – Utilize “Digital

Thread” across NAE

# 4 – Update Business and

Acquisition Processes

Goals Tactical Focus Areas Projects

ALRE Release

Element

LEX Fitting

Bathtub Repair

CH-53K Gearbox

Spike Canard

EMAM

Digital Thread

Cost Model*

Supply

Integration*

*Still in work

NAVAIR Additive Manufacturing Tactical Focus Areas

15

Casting Replacements

Structural Repair/Replacement

ALRE/SE Components

#1 - Field AM Parts

#2 – Demonstrate Rapid

Qualification/Certification

Initiative #1 Projects

AM Tooling Process Standard

Candidate Parts

Industry/DoD/Other

Initiative #2 ProjectsMaterial and Process Qualification

Non-Destructive Inspection Methods

Innovative Process Models

Industry/DoD/Other

Weapons and Energetics

Structural Analysis and Structural Certification

Complex Engine Components

NAVAIR Additive Manufacturing Tactical Focus Areas

16

3D/Model Based Environment

3D Modeling and AM Digital Environment

Initiative #3 Projects

AM Data Architecture/Standards

Industry/DoD/Other

Initiative #4 ProjectsNAVSUP and DLA Supply Chain

Cost Modeling and ROI

Industry/DoD/Other

# 3 – Utilize “Digital Thread” across NAE

# 4 – Update Business and Acquisition Processes

AM Build Package Development


Closing Comments

• DoD Maintenance faces unique challenges

• Aging infrastructure, Obsolescence issues, Service Life Extensions, Accelerated OPTEMPO

• Mandate to reduce Total Operating Costs of existing platforms while at the same time introducing new platforms

• New technologies (AM and others) will:

• Improve maintenance processes & procedures

• Positively impact availability, reliability, & maintainability

• Expanded AM build volumes, lower cost materials and faster through-put needed for expanded use in the

manufacture of large air vehicle parts

• BAAM (ORNL)

• Sheet metal tooling applications

• Composite tooling applications

• Efforts today prepares DoD Sustainment Community for a future of weapon systems built with increasing

AM technology

• Encourage collaboration within DoD services and with academia & industry to move sustainment

technologies forward

• Increased exposure to new technologies in the DoD workforce creates new innovative opportunities and ideas

• AM, 3D digital data, PLM enterprise software and connectivity will increase collaboration across FRC’s,

competencies and disciplines

17

Additive

Manufacturing

Air Force

Perspective

Tom Naguy

HQ AFMC/A4U

19 NOV 14

Air Force Materiel Command

One Team, Delivering Capabilities to Fly, Fight & Win…Today & Tomorrow

Additive Manufacturing Defined

•Additive Manufacturing (AM)

cost savings / reduction of depot costs

readiness improvements

Powder Bed Fusion

Directed Energy Deposition

Materials Extrusion

Materials Jetting

Binder Jetting

Sheet Lamination

AM - Processes in which

successive layers of

materials are laid down

under computer control…

AM enables new designin which geometric complexity is not a constraint and material can be located by choice

Expanded

Component

Geometries

Unintended

Spares and

Obsolescence

Current Issues:• Long Tooling Lead Times

• Low Production Volumes

• Material Substitution Re-certification

Potential for• Improved Lead Times

• Reduced Cost

Multiple component families geometries are

constrained by conventional manufacturing

capabilities, including ducting, fuel nozzles,

heat exchangers and turbine airfoils

Today

Future

Component

Repair

Current Issues:• Current components NOT

designed FOR repair

• Unvalidated repair processes and inspection requirements

Potential for

• Repair-able

components

• Reduced

Sustainment Burden

AM Aerospace Opportunities

Expanded

Component

Geometries

Potential for

• Part Consolidation

• Lead-Time Improvements

• Performance Benefits

• Tools, fixtures, prototypes, non-critical parts

• Hybrid tooling/ fixtures integrated with metal subcomponents

• Rapid prototyping for form, fit, and function

Immediate Value

• Manufacture of metal fixtures, masks, and jigs for repair process

• Manufacture of DMSMS components

• Manufacture of non-rotating and structural aircraft components

Mid - Long Term Outlook

• Effective dimensional metallic restoration of propulsion items

• Better microstructural control

• Manufacture of parts On-Demand

• Near Net Form Castings & Extrusions

Game-Changers

Air Force AM Implementation Strategy

• Considerations for Implementation of AM

– Demonstrated Process Controls

– Nondestructive Evaluation & Quality Assurance

– Post-Deposit Processing & Residual Stress Management

– Statistically-Based Mechanical Property Database

• Constrains− Lack of property databases, inadequate design tools− Lack of constrained process controls− Continually-changing, local processing environment with

changes in geometry and process parameters − Post-deposit distortion and residual stress − Undefined post-processing requirements− State of maturity for successful transition

− Stabilized material and/or material process− Producibility− Characterized mechanical properties− Predictability of structural performance− Supportability

• Qualification Process− Airworthiness (AW) approach across Enterprise for deploying New or Substitute

Materials, Processes, and Product

Why AM Implementation Is a Challenge

• Purpose

Formal process for Materials & Processes (M&P) changes is needed for aircraft applications

• AW: Why to use it

Many new M&P changes are cross-cutting and present unique challenges that must be characterized for the intended service environment, usage, and duration

Approval or disapproval should be documented by the appropriate authority, recognized by all AFMC and DLA personnel as a minimum, and implemented in each application

• AW: Benefits

Ensure M&P changes are fully qualified prior to implementation

Encourage implementation of M&P changes when business case is favorable

Implementation through

Airworthiness Approach

A

• Preliminary Evaluation• Define enterprise new/substitute

materials, processes, and product forms

• Identify applicable weapon systems

B

• Airworthiness Plan and Certification Basis Development• Identify AW and Qualification Plan

(existing and additional testing)

C

• Business Case Development/Endorsement• Endorsement by Key Senior Stakeholder(s)

D• Compliance Review

• Determine Certification Compliance

E• Implementation

• SPM submits Implementation Plan

Technology

Deployment

AW Process for Deploying New or

Substitute Materials, Processes, and

Product Forms

Entr

ance

to

AW

p

roce

ss

AM Technology

(materials/process/

product form) has

been properly

evaluated

5 primary factors

entrance criteria are met:

• Stability

• Producibility

• Characterized

Mechanical & Physical

Properties

• Predictability of

Performance

• Supportability

Techn

olo

gy Q

ualified

AM Qualification Process

FOR OFFICIAL USE ONLY


26

Additive Manufacturing for DoD

Maintenance Activities

November 19, 2014

Stacey Clark Kerwien

Deputy Division Chief, Materials, Manufacturing

& Prototype Technology

US Army RDECOM-ARDEC



This document contains information exempt from mandatory disclosure under the FOIA Exemption(s) ___________ apply



27

BLUF

• Additive manufacturing technologies bring the promise of enhanced performance with the

flexibility of manufacture at the point-of-use.

• While this technology is powerful, there are also important considerations and limitations:

– Each part is unique, therefore certification/qualification of the material and process are paramount

• Because industry views AM process data as proprietary, the product data needed to guarantee part performance is not available and is closely held as IP

– There are very limited published standards and much of the work is still in progress

– There are a limited number of machines, additive processes and materials available from the equipment manufacturers

– Material performance is not “as advertised” on the OEM data sheets and not fully characterized for all use cases

– No full materiel released – no systems in the field using additive parts

To ensure that Additive Manufacturing delivers on the promise, it is important to manage expectations and develop the proper foundation necessary to ensure reproducibility of AM components



28

Agenda

• What are the Goals for using AM in maintenance activities?

• What are the Challenges?

• What are we doing / What do we need to get there?



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Goals

• The goal is to make Additive Manufacturing as

accessible to use as machining, welding, etc.

• Develop standards that are substantive

• Use digital product data!!

• Populate materials databases with AM materials

and processes

• Manage expectations regarding the use of AM.



30

Agenda






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Summary of Major Technology Challenges

• Each part is unique, therefore certification/qualification of the

material and process are paramount

– Part quality is tied closely to process parameters, therefore processing conditions must be defined to ensure a quality part

– Because industry views AM process data as proprietary, the process data needed to guarantee part performance is not available and is held as IP

• AM standards are not available – much of work is still in progress

– The relationships between materials, process and performance have not been established, so standards development is slow

– In specific cases, companies have established their own standards, which they retain as proprietary

• There are a limited number of machines, additive processes and

materials available from the equipment manufacturers

– Material performance is not always “as advertised” on the equipment mfr. Data sheets and not fully characterized for all use cases

• No full materiel release – no systems in the field using additive parts

– The few cases where additive has been used to produce a part are on an exception basis: SOCOM, REF for spares, repairs and/or tooling

The goal is to make Additive Manufacturing as “available” as traditional manufacturing techniques.



32

Summary of AM Acquisition Challenge

• Additive Manufacturing, like all manufacturing requires

CAD model data to make a part

– Traditional processes require models, but these are often generated as part of the manufacturing process – standards are in-place to assure part quality

– Additive manufacturing requires a 3-D model and is highly dependent on process data to make a quality part, so both geometry data (CAD) and machine process data are essential

• The Army does not regard digital models as “official data”

and does not typically store or provide 3-D part data or

process information in its product data libraries

– The official data record is .pdf, models are for reference only

– Process data is almost never stored, as companies view it as proprietary

– Companies typically re-master product data by creating 3-D data from government provided .pdf’s and developing company specific CAM data – part quality comes through final inspection and the use of standards through the manufacturing process

Until Standards and Machine Technology Mature, the Army must store both product and process data for AM – to inform standards and make quality parts.



33

Agenda






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How Do We Get There: Strategy

• How are we “getting there” currently: one NSN at a time…until we

address the issues of qualification and certification

• An Army investment strategy is based upon looking at the common needs

between Army systems and value proposition to customers – an analysis

of alternative and customer input to maximize transition potential and

minimize the current “part-by-part” demonstrations

• With ~186,000+ items (managed by DLA) in Army inventory, the goal is to

demonstrate the use of AM for 1% of them within 5 years

– Need to assess good candidates for AM (long lead time items, items that need

to be forged or cast, items made with expensive materials, complex geometries



35

Concept

• Establish a data repository where additive process are recognized

as known alternative methods for manufacture of parts

– REF Parts Library, DLA

• Build data repository using processes consistent with government

product data storage methods

– JDMTP Effort to store information in MSAT

• Make part information (geometry) and process (manufacturing) data

available so parts can be made using known additive processes

– Army AM Community of Practice to perform Round Robin builds

• Establish business rules for using product data information to make

acceptable parts

– Army ManTech Program

• Provide guidance to buyers and manufacturers on parts that can be

made using additive processes35



36

Notional Architecture

COTS Parts Definitions

Digital Product

Definition

Custom Web Portal

WindChill10.1, Forward Facing on the DREN

Product Structure Per Component

Library of Components, Product CM

Process Definition Accessible Via Net

Final Product Produced in Field



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Additive for Rapid Fielding and Spare Parts:

• Additive manufacturing can provide point-of-use manufacturing for non-critical parts

• Supporting REF and CASCOM to establish library of parts “Digital Catalogue” of Additive Manufactured Parts for field sustainment

• Reduces logistics burden and lead-time for spare parts

• Capability envisioned: additive processes in field forward

environment supported by digital parts library

• Cost to implement: Working with REF/CASCOM on scope and resources to implement

REF Expeditionary Lab Concept

Mini Track BotDesigned as an ultra portable bot forcamera surveillance in any terrain.Operated by a small touch screencontroller with adequate range forthe soldier to standoff at a safedistance.

Weight: 2 poundsDimensions: 8” x 7” x 5”

Status: Approved for printing

Capability Envisioned (FY15-19):

Adoption Stage 1



38

Summary

• Additive Manufacturing is an enabling technology that has

the potential to provide a step function increase in cost

reduction and functionality

• Additive Manufacturing directly aligns with the Army’s goals

to support of novel designs, rapid fielding, prototyping and

reducing sustainment costs

• Army must develop and resource an enterprise-wide Additive

Manufacturing strategy to ensure Army systems can take advantage of this technology



39

Thank you

Documents

Additive Manufacturing Opportunities within DoD …sae.org/events/dod/presentations/2014/11-19/additive_manufacturing...Additive Manufacturing Opportunities within DoD Maintenance